Our gearbox woes

Hi all,

You may be interested in our adventures in Symphony in Mulhouse.

Our gearbox has always had a difficult gear change (at least since we bought it in Feb) but whilst travelling from Mulhouse to Freiburg to Furtwangen, we experienced van shudder when pressing the accelerator (hardish) when in fifth gear.

Basically, in fifth, and using the throttle hard results in van judder. I think it's also there (albeit, only a little) in fourth.

We visited a Peugeot dealer in Mulhouse where the service department did a test drive and suggested 5th was on it's way out. The [You must be registered and logged in to see this link.] was checked and then changed... see the photo.

Now we need to find a suitable gearbox specialist. Searching the forum finds Manual Gearbox Repairs in Swansea (not that far from us) and M&W Autos in Wisbech, the internet finds [You must be registered and logged in to see this link.], and [You must be registered and logged in to see this link.] who quoted £1495 inc VAT and free fitting if the van was left with them and 12 months warranty and 12k miles.

Has anyone used these and if so what was your experience?

With regards the drain pipe pouring water on top of the gearbox issue, I found [You must be registered and logged in to see this link.] sold the longer pipe (£21.62 inc). The chap I spoke to said Fiat redesigned the pipe in 1998...

Note: there's no crunching of gears (just difficulty in getting into gear), there's no steering wheel wobble which could indicate a wheel unbalanced, no clutch judder or slip. Although the chap at Coastal Motorhomes suggested checking the engine and gearbox mounts as the rubbers can perish. I have yet to do this.

For the judder, I would suspect the engine and gearbox mounts before the gearbox. I would ~expect~ a lot of noise from the gearbox if internal wear were so bad as to cause it to judder.

On the difficult gearchange, I'd want to be absolutely sure that linkage lubrication and adjustment did not fix the problem before doing anything to the gearbox itself - because that should be way, way cheaper to address!

Is that a trick of the light in the photo, or was the gearbox oil really cream coloured?

M&D wrote:

We visited a Peugeot dealer in Mulhouse where the service department did a test drive and suggested 5th was on it's way out. The [You must be registered and logged in to see this link.] was checked and then changed... see the photo.

The oil looks like it has been contaminated with water and has emulsified.
The damage may have already been done.

There is a thread about the scuttle drain hose being rerouted away from the gearbox.

PB

My 1998 Harmony is currently with Maurice at M&W Autos having the gearbox stripped and rebuilt with whatever new parts are needed. He get's them direct from Italy and is referred to elsewhere on this forum. The downside is he's in Wisbech down a single track country lane which from Southampton where I live is the equivalent of the dark side of the moon. He gave me a courtesy car and it took me 6 hours to drive home via a very tasty and a bit expensive all day breakfast at Baldock Services on the A1M !
These guys are a gem and hard to find as 'normal' garages just tell you the parts are obsolete- don't get me started !
My cheque book is already quivering at the potential cost but my Harmony is a lifetime investment so needs must.
I'll be writing up the outcome at a later date.
Terry

Found it- [You must be registered and logged in to see this link.]

Thanks for your replies, Mojo, PB and Terry. And yes, that really is the colour of the oil, magnolia I think is the modern name for that colour. And 2.5ltr came out of the gearbox...

I changed my lemon Mk4 engine oil many years ago and that at least had some black (oil) streaks in it!

I'm hoping to 'fiddle' with the engine/gearbox mounts this coming weekend, and I also hope to fit the 'longer' pipe...

Hi again, and apologies for the loong delay in replying/updating. It really isn't worth going into the why, so as I'm frequently told, ziiip.

To bring you up to date, I changed the engine and gearbox mounts with lovely shiny new rubber mounts. But it didn't change a thing. I then had the gearbox rebuilt by Gloucester Road Gearboxes. Fantastic, I can now obtain 3rd and 4th gears. I also had them replace the other driveshaft, both now new. But it didn't stop the shuddering.

Next step: I replaced the ignition leads, spark plugs and the coil (thing). I believe it runs smoothly now, but I'm not sure. As then the engine light came on (which the manual says is either ignition or injection).

At this time, I was also trying to get things sorted for the MOT which obviously had to be done, and other than surgery on the sills the MOT was issued. Part of the repair work was finding out what was wrong re the engine light.

The garage first said these vans don't have OBD, and then after being pointed to the grey/green 2 pin plug said they don't have the test equipment. So no repair.

So, after months of this and sitting waiting for the right garage to jump in front of me, we have a lovely camper with an engine that turns over but won't start and an RED engine light...

I need an FCR... I've found the Haynes/Draper version online but only for the Audi/VW and Ford/Opel/Vauxhall. Anyone know of a Puegeot version I could beg, borrow or er., buy?

Many thanks, Mark.

Mark
Is the 'Citroen Relay Peugeot Boxer 1.9 and 2.5 litre diesel workshop manual 1994-2001' any use ? I have an owners edition if that helps and will be in Bristol over Easter weekend if that helps, otherwise I could post it to you ?
Also, with your vin number I might be able to get specific diagrams from the Peugeot Citroen service box.
Terry
ps I feel your pain !!

Thanks Newterry. I do have the Peter Russek 2.0i version. But there's nothing in there regards the warning light. There's 5 pages on the injection system which just talks about the system, but no clues regards faults. Ditto ignition, 3 pages, half of which are about the spark plugs. Apologies, it looks like I forgot to mention in my profile thats its a petrol Symphony '99.

Mark
Ok, a very different animal !!!
Terry

M&D wrote:Thanks Newterry. I do have the Peter Russek 2.0i version. But there's nothing in there regards the warning light. There's 5 pages on the injection system which just talks about the system, but no clues regards faults. Ditto ignition, 3 pages, half of which are about the spark plugs. Apologies, it looks like I forgot to mention in my profile thats its a petrol Symphony '99.

I  think you want a new thread on your engine problem. Its not the gearbox.

regards

Micky